DIY fabrication of Simplicity® should not be challenging for those with at least some
mechanical skills. No special tools are required. Need to fabricate PVC panels also?
Not a problem, simply cut a second set of frames and spline in the PVC film in the
exact same fashion as insect screen material - except looser. You want to allow for
slight vinyl shrinkage during cold weather.
Our recommended tool list and installation
instructions should accommodate most people and projects. You may use any equipment,
tool or process that you feel will work better or best fits your skill level. You
can adjust our instructions in any fashion needed to best fit your application.
A Miter Saw suitable for cutting metals and properly equipped with a blade approved
for aluminum cutting -or- a hack saw and miter box.
A work table or area that is at least as large as the largest panel to be assembled
Screen material installation tool
Possible Additional Tools Required (needed only for center bars):
1/8" Drill Bit(s)
1/8" x 1/4" Rivets and Rivet Gun
Table Saw suitable for cutting metals and properly equipped with a blade approved
for aluminum cutting -or- a hack saw and miter box.
Work safely and follow all common safety practices and use all proper safety equipment.
Be sure that you are proficient with any tool or equipment used and that all tools
or equipment used is properly suited for the work being performed.
The following recommended instructions assume that you have properly planned your
sizes and have received all required components. (Frame Materials, Corner Inserts,
Screen Material, Spline, Center Bar, and Rivets (if needed)
You must account for 1" per square cut corner when calculating your cut lengths.
For example, if your screen width is 32" you would cut your frame to 30". 30" + 1"
per corner will result in a 32" frame. Remember to account for this on all lengths
of metal and for both the height and width. If you use MITER CUT corner inserts,
cut your metal to the size(s) required.
Cut frame material to the proper adjusted length. (Remember you'll need 2 for each
height and 2 for each width)
Use a cutting jig, (material stop) if possible, to ensure
all pairs are cut to the exact same size.
When cutting for mitered corners, the spline
channel must be cut to the inside of the angle and do not stack cut metal when cutting
Check your cuts as you go or during assembly.
will be snug - a small mallet may help with assembly.
Assemble the frame one leg
at a time until complete. Once assembled move on to center bar installation or screen
Support bars for Simplicity® screens are recommended for both screen and PVC panels
with a height or width over 48" and must be installed prior to screen or PVC installation.
Support bars are structural and provide a substantially sturdier frame.
In screen panels, install support bar perpendicular to the longest sides. Typically,
screen support bars are installed at 36" up from base or to a height best suited
for your application. Failure to use bars as recommended may result in an hourglass
effect and/or loose screen material.
Support bars are highly recommended on all PVC panels with a height or width over
48". Support bar must be centered perpendicular to the longest sides. Failure to
use bars as recommended will result in an hourglass effect and a substantial risk
of blow out during high winds.
Center bar should be sized to 1/16" less than the total dimension. Example: cut a
center bar support at 35-15/16" for a 36" wide screen) Cover exposed face with painters
tape or other removable protective film prior to notching. This will help prevent
Remove a 1" (notch) from each end. Material is removed from the spline side. This
may be done with a properly outfitted table saw, milling machine, hack saw, etc. (use
of table saw shown above) Leave only the back wall of the frame.
Your cut should be clean and burr free. Test fit prior to removing protective tape.
If you need to reduce the length for fit, remove only a slight amount at a time from
one end only. (Cut a small amount off of 1 arm and them and re-notch) Repeat as needed
to produce a snug fit.
Once bar is correctly sized and positioned, drill and rivet into place.
Install screen material in the standard fashion. Watch your screen installation closely,
if you install in an extremely tight fashion you will run the risk of "hour glassing".
Jig your frame if needed. Use .200 polyfoam spline for all screen materials.
Install PVC in the exact same fashion as screen material using the same size spline.
DO NOT install tight - there must be some flex or looseness to the film. During cold
weather the PVC will shrink roughly 2%. This shrinkage is normal and will result in
a firm panel.
Please follow all common safety practices and use all proper safety equipment. Be
sure that you are proficient with any tool or equipment used and that all tools or
equipment used is properly suited for the work being performed.
Panels manufactured outside of our production facilities are not covered by the Connecticut
Screen Works® limited warranty. All information and directions provided should be
treated as generic guides which are intended to help you plan, measure and order screens.
Our directions are applicable and correct for a great majority of situations - but
not all. In some situations they may need to be modified. In some situations they
may not be applicable at all. The responsibility to determine this and the responsibility
to order items correctly rests solely on the customer. We make no guarantee, warrantee
or promise of any kind that the directions (guides) we provide will work in every
application. Please read and understand all information provided on this web site.